Industry Focus Automotive Supply Chain


A logistical boost M


agna’s facility supplies injec- tion moulded internal door panels for two different vehi- cle models, working on a just in time basis with a four hour notice period for incoming orders. Whilst the operation only manufac- tures door panels for two vehicle models, there are a number of different variations for each. Owing to a planned model change, Magna Automotive was required to increase the number of panel variations to handle the requirements for both the outgoing and new vehicle, which meant an increase in the number of variances of around 17%. Therefore, additional space was needed to accom- modate extra production equipment.


The solution


SDI Group UK was invited by Magna Automotive to design an automated system for the storage and retrieval of the panels. A bespoke, turn-key solution was required to optimise the existing facility, freeing up valuable space for new equipment, whilst avoiding any disruption to the ongoing operation. Working with SDI Group UK, SolutionsPT was asked to consider a range of requirements that included enhanced workforce productivity; max- imising capacity for future business wins; and increasing operational visibil- ity and control. In addition, any solution would have to take into consideration the unique needs of a just in time opera- tion, which demanded particularly high levels of accuracy, timeliness and prod- uct quality.


The facility had originally been built with a ten metre clear eve height, yet the highest piece of machinery was a mere four metres. Therefore, around 60% of the cubic volume of the build- ing was unused. With this in mind, SDI created a two floor mezzanine structure measuring 1,700m2 achieved more than 950m2 tional production space.


which of addi-


This enabled Magna Automotive to handle the increased number of prod- uct variations, and effectively achieve a maximum daily throughput of 1,330 completed door panels, that are man- ufactured, stored and distributed within the facility.


A key feature of the WCS


(Warehouse Control System) is the easy to use touch screen operator


24


interface using InTouch software from SolutionsPT. The operator screens were designed for ease of use and minimal operator input.


Each PC node provides detailed diagnostic information to engineers and operators right on the plant floor.


Implementation


Completed within the required time frame, Magna Automotive was able to meet the delivery deadlines for new parts to its customer’s car production line. Zero down-time was achieved throughout, ensuring that Magna Automotive was able to continue to serve its customer without disruption throughout the course of the installation. An essential aspect of the solution was a Warehouse Control System (WCS) that was developed to meet the precise


Wonderware’s System Platform, supplied by SolutionsPT, provided the solution for Magna Automotive, a supplier of components to the automobile industry, when it had to re-vamp its manufacturing facility in Burton-on-Trent


Right: the Burton-on-Trent facility is part of Magna


Automotive’s Interiors Division, supplying injection moulded internal door panels for two different vehicle models


tested, then an object ‘instance’ is deployed wherever an identical (or similar) item has to be automated. Detail within an object appears in a standard directory/sub-directory struc- ture - providing a clear and useable overview and the ability to tailor an instance where a non-standard element has to be automated. The WCS uses Wonderware System Platform and six Wonderware InTouch nodes for visualisation and supervisory control. The system’s natural connectiv- ity takes care of communications to automation controllers and external databases. History and trend informa- tion is available within the system which as the production facility matures, will provide detailed insight into operational performance and there- fore a sound basis for continual improvement programmes.


Return on Investment


needs of Magna Automotive. This user software would provide overall control at each stage of the production process from manufacture of parts, through to storage and then transfer to production areas and drop-off points.


For the real time automation supervi- sion of the system, the Warehouse Control System, SDI chose Wonderware’s System Platform from SolutionsPT.


Nigel King, senior software consul- tant, SDI Group, said, “Wonderware’s object technology, especially with the new capability to have embedded graph- ics within an object in Version 3, was a huge benefit to the project timeline. Having both hardware and software being supplied by the same company minimised a lot of potential risks.” System Platform was designed with real world project experience in mind, objects can be designed and rigorously


Above: Magna Automotive now has a far more efficient production system which will provide business benefits long into the future


of additional ground floor production space, increasing capacity to meet production needs and handle future growth. The materials han- dling solution was completed within the required timeframe with zero operational down-time.


Utilisation was improved by freeing 11,500ft2


Productivity was increased as was available workforce, equating to a head- count redeployment of eight percent - combined with enhanced control such as improved stock control, production planning, and inspection of stock pro- duced, as well as adding advanced, automated reporting capability. Magna Automotive now has a far more efficient production system which will provide business benefits long into the future. The utilisation of Wonderware’s System Platform in the solution, pro- vided by SolutionsPT and SDI Group, will continue to provide measurable cost savings in operation and when inevitable changes to production occur.


SolutionsPT www.solutionspt.com T: 0161 495 4600


Enter 207 OCTOBER 2013 Automation


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